Depth Setter Assembly for Precise Flush Fastener Seating
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Solution Overview
Problem
Existing fastener systems lack an efficient method to set fasteners at a precise depth within a workpiece without separate counterbore and driving processes, often resulting in incomplete concealment of the fastener head.
Innovation Solution
A depth setter tool assembly comprising a snap-fit or press-fit elongated spacer around a driver bit shank, combined with a compliant stopper that restricts axial movement, allowing the fastener to be driven to a predetermined depth while the driver bit continues spinning, ensuring the fastener head is flush or slightly below the workpiece surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a separate counterbore process followed by a driving process is used, then the fastener can be set at a given depth within the workpiece, but the operational complexity and time consumption increase
Solution Approach 1:
The patent combines the counterbore process and the driving process into a single integrated operation using one tool. The tool features a counterbore component that creates a recess and a driving component that sets the fastener, both accomplished simultaneously rather than as separate sequential operations. This merging eliminates the need for tool changes or separate processing steps while maintaining precise depth control.
Solution Approach 2:
The tool is designed with multi-functionality, serving both as a counterbore tool and a fastener setting tool. The single tool performs multiple functions: creating the counterbore recess, guiding the fastener, and driving the fastener to the correct depth. This universal tool replaces what would traditionally require at least two separate specialized tools.
2Device complexity
If the fastener is driven below the workpiece surface to a pre-determined depth in a single action, then the operational complexity is reduced, but achieving precise depth control and complete concealment becomes difficult
Solution Approach 1:
The tool performs preliminary action by creating a counterbore recess before the fastener is driven into the workpiece. This pre-created recess provides a receptacle for the fastener head, ensuring that when the fastener is driven in a single action, its head will be properly contained within the recess rather than protruding from the surface. This preliminary counterboring action enables complete concealment while maintaining single-action simplicity.
Solution Approach 2:
The counterbore recess acts as an intermediary structure that mediates between the driving force and the workpiece surface. It provides a controlled environment for the fastener head, allowing the driving component to push the fastener to the correct depth without the head interfering with the surface. This intermediary recess enables precise depth control even in a single-action operation.
3Productivity
If a single-action driving process is used, then productivity is improved, but the ability to conceal the fastener head completely is compromised
Solution Approach 1:
The tool merges the counterbore creation and fastener driving functions into a single integrated action. As the tool engages the workpiece, it simultaneously creates the counterbore recess and drives the fastener into position. This combined action maintains high productivity while ensuring the fastener head is properly concealed within the recess, eliminating the need for separate operations.
Solution Approach 2:
The tool performs preliminary counterboring action as part of the single driving motion. The counterbore component prepares the recess space in advance during the same motion that drives the fastener, ensuring the head will be concealed. This preliminary action embedded within the single operation maintains productivity while achieving complete concealment quality.
Data Source
AI summary
A depth setter tool includes a spacer having an inner diameter sized to fit around a shank of a driver bit such that the spacer can rotate about an axis passing through a center of the driver bit and independently of the driver bit. The spacer further includes an opening extending along an entire length of the spacer from a first end of the spacer to a second end of the spacer. The opening provides access to the inner diameter thereby allowing the spacer to be engaged onto the shank of the driver bit. The depth setter tool also includes a stopper. In an example, the stopper is donut-shaped and includes a compliant material that engages around the first end of the spacer.